Joint structure of electric wire, stator of rotary electric machine, method for manufacturing the same

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 11/438,591 filed May 23, 2006.

CLAIM OF PRIORITY

The present application claim priority from Japanese application Ser. No. 2005-150316, filed on May 24, 2005, the content of which is hereby incorporated by reference into this application.

FIELD OF THE INVENTION

The present invention relates to a stator of a rotary electric machine such as, for example, an AC generator for a vehicle and a method for manufacturing the same, as well as a joint structure of electric wires and a method for manufacturing the same.

BACKGROUND OF THE INVENTION

According to a known electric wire, an end portion of an electric wire (a joint conductor) which end portion extends over a predetermined range from a tip of the wire is plastically deformed so that a sectional area thereof becomes smaller than that of a main portion of the conductor, and the wire is constructed so that the main portion and a part of the end portion near the main portion are coated uniformly with an insulating film, then two such electric wires (joint conductors) are joined together in a matched state of respective end portions.

[Patent Literature 1]

Japanese Patent Laid-Open Publication No. 2002-95198

In the above conventional technique, since the sectional area of the end portion is decreased while preventing damage of the insulating film, a heat input quantity can be decreased. Consequently, there is no fear that an insulating material located near a joined portion may be deteriorated with heat produced a joining work, and hence the insulating performance is not impaired.

In the above conventional technique, however, if two electric wires (joint conductors) are positioned adjacent each other in a peeled state of respective insulating coatings, there is formed a gap with corresponding to the total thickness of both conductor's insulating coatings as skin layers in a joined face portion between end portions of the conductors. The gap becomes larger because the conductors are tapered at their tips. Therefore, the adhesion between both conductors is impaired, with a consequent fear of occurrence of joining imperfection.

It is an object of the present invention to minimize the gap developed between electric wires (joint conductors), thereby improving the reliability of joining, and facilitate the conductor joining work, thereby improving the productivity of a state of a rotary electric machine such as, for example, an AC generator for a vehicle.

SUMMARY OF THE INVENTION

The present invention provides an electric wire joint structure comprising:

insulator-coated wires each having a portion where an insulator coating is removed to expose the conductor, wherein exposed portions of the conductors are opposed to each other to form joining faces; the joining faces of the exposed portions being flush with the surfaces of the insulator coatings of the insulator-coated wires or being projected from the surfaces of the insulator coatings of the insulator-coated wires, and the joining faces being metallurgically joined.

According to one aspect of the present invention, for achieving the above-mentioned object, in opposed joined face portions of electric wires (joint conductors), the axes of the conductors' exposed portions are offset relative to the axes of the insulating coating in such a manner that exposed tip portions of the conductors and insulating coating faces located in the vicinity thereof are flush with each other or the conductors' exposed portions are projected.

According to another aspect of the present invention constructed as above, since joined faces of the joined face portions at the tips of the conductors with insulating coatings removed confront each other, it is not necessary to keep the two pushed against each other with a strong force during the joining work. Besides, it is possible to diminish the likelihood of peeling-off of the joined face portion caused by spring-back after joining. As a result, not only the rationalization of the joining work can be attained, but also the reliability of the joined state of the joined face portion is improved and so are the productivity and reliability of, for example, the stator of a rotary electric machine.

BRIEF DESCRIPTION OF THE DRAWINGS

<figref idref="DRAWINGS">FIG. 1</figref> is an enlarged perspective view showing a connection between electric wires (joint conductors) to which the present invention is applied;

<figref idref="DRAWINGS">FIG. 2</figref> is a diagram illustrating a process of cutting joined face portions into a shape easy to weld;

<figref idref="DRAWINGS">FIG. 3</figref> is a diagram showing a welded state of the joined face portions;

<figref idref="DRAWINGS">FIG. 4</figref> is a diagram for explaining in what state the joined face portions are Tig-welded;

<figref idref="DRAWINGS">FIG. 5</figref> is a diagram showing a process of chipping off enamel coatings on short sides;

<figref idref="DRAWINGS">FIG. 6</figref> is a diagram showing a process of chipping off enamel coatings on long sides;

<figref idref="DRAWINGS">FIG. 7</figref> is an enlarged diagram of a circular frame portion in <figref idref="DRAWINGS">FIG. 5</figref>;

<figref idref="DRAWINGS">FIG. 8</figref> is an enlarged diagram of a circular frame portion in <figref idref="DRAWINGS">FIG. 6</figref>;

<figref idref="DRAWINGS">FIG. 9</figref> is an appearance diagram of a chip-off device;

<figref idref="DRAWINGS">FIGS. 10A to 10D</figref> are diagrams for explaining a process of chipping off enamel coatings on shorts sides;

<figref idref="DRAWINGS">FIG. 11</figref> is a perspective view showing insulated conductors after chipping-off of the short-side enamel coatings;

<figref idref="DRAWINGS">FIGS. 12A to 12F</figref> are diagrams for explaining a process of chipping off enamel coatings on long sides;

<figref idref="DRAWINGS">FIG. 13</figref> is a perspective view showing the insulated conductors after chipping-off of the short- and long-side enamel coatings;

<figref idref="DRAWINGS">FIG. 14</figref> is a diagram showing a state in which the insulated conductors after chipping-off of the short- and long-side enamel coatings have been set to a cutting device;

<figref idref="DRAWINGS">FIG. 15</figref> is a diagram for explaining another machining method;

<figref idref="DRAWINGS">FIG. 16</figref> is a diagram showing base metals of coil conductors used in a stator of a rotary electric machine;

<figref idref="DRAWINGS">FIG. 17</figref> is a diagram showing bent coil conductors;

<figref idref="DRAWINGS">FIG. 18</figref> is a diagram showing an inner coil and an outer coil each formed in the hexagonal shape;

<figref idref="DRAWINGS">FIG. 19</figref> is a diagram showing a part of a stator of a rotary electric machine according to the present invention;

<figref idref="DRAWINGS">FIG. 20</figref> is a diagram for explaining a process to be carried out prior to a stator assembling process;

<figref idref="DRAWINGS">FIG. 21</figref> is a diagram for explaining another process to be carried out prior to the stator assembling process;

<figref idref="DRAWINGS">FIG. 22</figref> is a diagram for explaining a state in which a stator core has been set to a stator assembling fixture;

<figref idref="DRAWINGS">FIG. 23</figref> is a diagram for explaining in which state inner coils are set to the stator core;

<figref idref="DRAWINGS">FIG. 24</figref> is a diagram for explaining in which state outer coils are set to the stator core;

<figref idref="DRAWINGS">FIG. 25</figref> is a diagram showing the stator core with inner and outer coils set thereto;

<figref idref="DRAWINGS">FIG. 26</figref> is a diagram for explaining a process of twisting the outer coils;

<figref idref="DRAWINGS">FIG. 27</figref> is a diagram for explaining a process of deforming and caulking the outer coils into a state necessary for joining;

<figref idref="DRAWINGS">FIG. 28</figref> is a diagram for explaining a process of welding joined face portions of the outer coils;

<figref idref="DRAWINGS">FIG. 29</figref> is a diagram for explaining a process of twisting the inner coils;

<figref idref="DRAWINGS">FIG. 30</figref> is a diagram for explaining a process of deforming and caulking the inner coils into a state necessary for joining; and

<figref idref="DRAWINGS">FIG. 31</figref> is a diagram for explaining a process of welding joined face portions of the inner coils.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of the present invention will be described hereinunder with reference to the drawings.

<figref idref="DRAWINGS">FIG. 1</figref> is an enlarged perspective view showing a connection between electric wires (joint conductors) to which the present invention is applied.

Electric wires (joint conductors) <b>1</b> and <b>2</b> respectively comprise conductors <b>1</b>A and <b>2</b>A of a rectangular section coated and insulated with enamel coatings <b>1</b>B and <b>2</b>B.

The enamel coatings <b>1</b>B and <b>2</b>B are chipped off at tips of the electric wires (joint conductors) <b>1</b> and <b>2</b> to form, at the tips, projecting portions <b>1</b>C and <b>2</b>C which are the smallest in sectional area. The small projecting portions <b>1</b>C and <b>2</b>C function as cutting portions when cutting a single long conductor (a detailed description will be given later) to form a conductor piece of a required length. Sectional area portions of a medium size, which function as welding portions <b>1</b>D and <b>2</b>D, are formed between the small projecting portions <b>1</b>C, <b>2</b>C and the enamel coatings <b>1</b>B, <b>2</b>B. One sides between the small projecting portions <b>1</b>C, <b>2</b>C and the welding portions <b>1</b>D, <b>2</b>D are connected together through first slant faces <b>1</b>E and <b>2</b>E having outward inclinations toward the enamel coatings <b>1</b>B and <b>2</b>B.

The welding face portions <b>1</b>D, <b>2</b>D and the enamel coatings <b>1</b>B, <b>2</b>B (portions of the largest sectional area) are connected together through stepped portions <b>1</b>F and <b>2</b>F.

Further, second slant faces <b>1</b>G and <b>2</b>G having outward inclinations toward the enamel coatings <b>1</b>B and <b>2</b>B are formed between the stepped portions <b>1</b>F, <b>2</b>F and the enamel coatings <b>1</b>B, <b>2</b>B.

The sides of the electric wires (joint conductors) <b>1</b> and <b>2</b> opposite to the side including the first slant faces <b>1</b>E, <b>2</b>E, and the stepped portions <b>1</b>F, <b>2</b>F are formed flat from the enamel coatings <b>1</b>B and <b>2</b>B up to tips of the small projecting portions <b>1</b>C and <b>2</b>C.

At the flat face portions, indicated at <b>1</b>H and <b>2</b>H, the tip portions of the joint conductors <b>1</b> and <b>2</b> are in close contact with each other.

This construction is characteristic in that there is no gap between joined faces formed by the flat face portions <b>1</b>H and <b>2</b>H. As a result, the heat dissipating area of the joined face portions diminishes by about 25% and it becomes possible to effect joining to a satisfactory extent with a relatively small quantity of heat during welding. Coupled with a reduced quantity of heat because of a small sectional area of the tip portions of the conductors, it becomes possible to conduct heating more effectively.

The remaining two faces at the tips of the electric wires (joint conductors) <b>1</b> and <b>2</b> are formed as flat faces <b>1</b>J, <b>2</b>J and flat faces (not shown) on the back sides.

Also on the flat faces <b>1</b>J and <b>2</b>J the enamel coatings <b>1</b>B and <b>2</b>B are chipped off to form third slant faces <b>1</b><i>k </i>and <b>2</b>K which are inclined outwards toward the enamel coatings <b>1</b>B and <b>2</b>B. This is also true of the back faces.

The first slant faces <b>1</b>E, <b>2</b>E, the second slant faces <b>1</b>G, <b>2</b>G, the third slant faces <b>1</b>K, <b>2</b>K, the flat faces <b>1</b>J, <b>2</b>J and their back faces are formed with edges of a cutter (to be described later) which chips off the coatings <b>1</b>B and <b>2</b>B of the conductors.

<figref idref="DRAWINGS">FIG. 2</figref> is a diagram explanatory of a process of cutting the joined face portions into a shape which facilitates welding.

Before welding, the tip portions of the electric wires (joint conductors) <b>1</b> and <b>2</b> are cut by operating cutting edges <b>20</b>A and <b>20</b>B of a cutter <b>20</b> in the directions of arrows in <figref idref="DRAWINGS">FIG. 2</figref> at intermediate positions (shown in <figref idref="DRAWINGS">FIG. 2</figref>) of the welding face portions <b>1</b>D and <b>2</b>D as portions of a medium sectional area.

<figref idref="DRAWINGS">FIG. 3</figref> shows a welded state of both conductors by Tig welding (Tungsten Inert Gas welding) on the cut faces.

<figref idref="DRAWINGS">FIG. 4</figref> illustrates in what manner the joined face portions are Tig-welded.

By welding the cut faces, indicated at <b>1</b>L and <b>2</b>L, by Tig welding (Tungsten Inert Gas welding), the joined faces of the electric wires (joint conductors) <b>1</b>A and <b>2</b>A are joined together by molten metal <b>30</b>.

More specifically, a heat-resistant tungsten electrode <b>42</b> is held in a collet <b>41</b> of a torch <b>40</b> and an inert gas (argon or helium gas) <b>44</b> is introduced through a gas introducing pipe <b>43</b> around the tungsten electrode <b>42</b> and is ejected through a gas nozzle <b>47</b> to around a welding portion. A jet <b>48</b> of the inert gas cuts off the welding portion from air, creating an oxygen-free state. As a result, the material is difficult to be oxidized because there is no oxygen (air) in the welding portion. Since the electric wires (joint conductors) <b>1</b>A and <b>2</b>A are copper wires, they are used as positive electrodes, while an electrode <b>41</b>A of the collet <b>41</b> is used as a negative electrode, and a DC voltage is applied, causing an arc <b>40</b>B to be produced between the tungsten electrode <b>42</b> and the joined faces <b>1</b>L, <b>2</b>L of the electric wires (joint conductors) <b>1</b>A, <b>2</b>A. In this welding, the temperature of the arc <b>40</b>B reaches a temperature of 5000 to 30000 degrees. With the heat of the arc <b>40</b>B, the joined face portion between the joined faces <b>1</b>L and <b>2</b>L is melted and welded.

The smaller the heat dissipating area and the smaller the amount of heat dissipated, the earlier the temperature of the welding portion can be raised up to the metal melting temperature.

Besides, since there is no gap between the joined faces, there is no sump of air (oxygen), and even if a negative pressure portion occurs in the welding portion by the flow of inert gas which is blown off against the welding portion, there is no fear of air (oxygen) being introduced (flowing reverse) into the joined face portion and the welding portion is so much difficult to be oxidized, because in the welding portion there is not such a gap as serves as an air introducing passage.

Since the joined faces are in close contact with each other, it is not necessary push the joined faces with a strong force from the exterior during welding. The problem that the joined portion springs back (a phenomenon that the joined portion repulses the pushing force and tends to revert to the original separated state) after welding, causing separation of the welded portion, is also solved. Further, it is not necessary to retain the pushing force until the joined portion gets cold for the prevention of separation caused by such a spring-back phenomenon, and the time required for the joining can so much be shortened.

When the electric wires (joint conductors) are joined in a stand-up state, the stepped portions <b>1</b>F and <b>2</b>F act as receiving portions of molten metal spatter, whereby the possibility of the spatter adhering to for example of the face of the insulating film and impairing the insulating property can also be diminished.

Now, with reference to <figref idref="DRAWINGS">FIGS. 5 and 6</figref>, a description will be given below about a method and apparatus for manufacturing the electric wires (joint conductors) <b>1</b> and <b>2</b> described above.

As also described earlier, the electric wires (joint conductors) <b>1</b> and <b>2</b> according to this embodiment are rectangular conductors whose section perpendicular to the longitudinal axis of each conductor is a rectangular section comprising long and short sides. The outer peripheries of the electric wires are coated for insulation with enamel coatings <b>1</b>A and <b>2</b>A.

In case of welding an end portion of a conductor to another conductor, the enamel coating thereof becomes an obstacle. Therefore, it is necessary to remove the enamel coating on the end portion of each conductor which portion serves as a conductor joined face portion to facilitate welding. Besides, the machining method should be a method suitable for automation so that the enamel coating removing work and a cutting work for cutting the conductor into a specific length suitable for the purpose of use are carried out.

<figref idref="DRAWINGS">FIGS. 5 to 12</figref> are drawings for explaining the enamel coating removing work, of which <figref idref="DRAWINGS">FIG. 5</figref> illustrates a process of chipping off the enamel coatings on short sides, <figref idref="DRAWINGS">FIG. 6</figref> illustrates a process of chipping off the enamel coatings on long sides, <figref idref="DRAWINGS">FIG. 7</figref> is an enlarged diagram of a circular frame portion in <figref idref="DRAWINGS">FIG. 5</figref>, <figref idref="DRAWINGS">FIG. 8</figref> is an enlarged diagram of a circular frame portion in <figref idref="DRAWINGS">FIG. 6</figref>, and <figref idref="DRAWINGS">FIG. 9</figref> is an appearance diagram of a chip-off device.

Chip-off devices <b>50</b> and <b>60</b> comprise fixed dies <b>51</b>, <b>61</b> and movable dies <b>52</b>, <b>62</b>.

The fixed dies <b>51</b> and <b>61</b> comprise a pair of fixed clamping fixtures <b>51</b>A, <b>51</b>B and a pair of fixed clamping fixtures <b>61</b>A, <b>61</b>B, respectively, and centrally provided, combined conductor guides and fixed blades <b>51</b>C and <b>61</b>C, respectively.

The movable dies <b>52</b> and <b>62</b> comprise a pair of movable cutting blades <b>52</b>A, <b>52</b>B and a pair of movable cutting blades <b>62</b>A, <b>62</b>B, respectively, and centrally provided, conductor pressers <b>52</b>C and <b>62</b>C, respectively.

The combined conductor guides and fixed cutting blades <b>51</b>C, <b>61</b>C and the movables cutting blades <b>52</b>A, <b>52</b>B, <b>62</b>A, <b>62</b>B have respective edges <b>51</b><i>a</i>, <b>51</b><i>b</i>, <b>61</b><i>a</i>, <b>61</b><i>b</i>, <b>52</b><i>a</i>, <b>52</b><i>b</i>, <b>62</b><i>a</i>, and <b>62</b><i>b. </i>

The chip-off devices <b>50</b> and <b>60</b> are installed side by side before and after a machining line. An enamel coating <b>100</b>A on each short side is first excised and this excised portion is fed to the position of the chip-off device <b>60</b>, where the enamel coating <b>100</b>A on each long side is chipped off. In this way enamel coating <b>100</b>A-chipped off portions are formed continuously at certain intervals on the long conductor.

As shown in <figref idref="DRAWINGS">FIG. 9</figref>, at an inlet and an outlet of the chip-off device <b>50</b> there are provided conductor feed guides <b>101</b> and <b>102</b>, respectively, for feeding straight an insulated conductor. An insulated conductor <b>100</b> which has been fed over a certain length by means of a feeder (not shown) is guided into a groove <b>51</b>F in such a manner that long sides of the conductor <b>100</b> come into abutment against the slot, the groove <b>51</b>F being formed in an end face of the combined conductor guide and fixed cutting blade <b>51</b>C in the chip-off device <b>50</b>.

As shown in <figref idref="DRAWINGS">FIGS. 5</figref>, <b>7</b> and <b>10</b>, the insulated conductor <b>100</b> is pressed down in the direction of the combined conductor guide and fixed cutting blade <b>51</b>C by means of the conductor presser <b>52</b>C which is disposed at a position confronting the combined conductor guide and fixed cutting blade <b>51</b>C, whereby the position of the insulated conductor <b>100</b> is fixed (see <figref idref="DRAWINGS">FIGS. 10A and 10C</figref>).

Next, the movable blades <b>52</b>A and <b>52</b>B move from above to below in the drawings, with the result that a shear force is developed between the edges <b>52</b><i>a</i>, <b>52</b><i>b </i>of the movable cutting blades <b>52</b>A, <b>52</b>B and the edges <b>51</b><i>a</i>, <b>51</b><i>b </i>of the combined conductor guide and fixed cutting blade <b>51</b>C. The drawings illustrate a state in which the coating is being chipped off with the shear force. The chipped-off coating and a part of the conductor (chips resulting from cutting) are held in gaps <b>51</b>D and <b>51</b>E formed between the fixed clamping fixtures <b>51</b>A, <b>51</b>B and the combined conductor guide and fixed cutting blade <b>51</b>C (see <figref idref="DRAWINGS">FIGS. 10B and 10D</figref>).

When the chipping-off of the enamel coating <b>100</b>A on short sides is over, the insulated conductor <b>100</b> is fed to the position of the next chip-off device <b>60</b> by means of a feeder (not shown).

<figref idref="DRAWINGS">FIG. 11</figref> shows an appearance of the insulated conductor upon completion of chipping-off of the short-side enamel coating <b>100</b>. The same constituent portions as in <figref idref="DRAWINGS">FIG. 1</figref> are identified by the same reference numerals as in <figref idref="DRAWINGS">FIG. 1</figref>.

The chip-off device <b>60</b> is disposed at a position corresponding to a 90°-rotated position of the chip-off device <b>50</b>. The movable cutting blades <b>62</b>A and <b>62</b>B of the chip-off device <b>60</b> are disposed on the same machining line so as to reciprocate perpendicularly to the movable cutting blades <b>52</b>A and <b>52</b>B of the chip-off device <b>50</b>.

Like the device shown in <figref idref="DRAWINGS">FIG. 9</figref>, the chip-off device <b>60</b> is also provided with conductor feed guides <b>101</b> and <b>102</b> at an inlet and an outlet, respectively, for feeding the insulated conductor straight. The enamel coating <b>100</b>A-chipped off portion on a short side of the insulated conductor <b>100</b> which has been fed a certain length by the feeder (not shown) is set to the position of a groove <b>61</b>F which is formed in an end face of the combined conductor guide and fixed cutting blade <b>61</b>C of the chip-off device <b>60</b>. In this state a gap is still present between the face of the chipped-off portion and the face of the groove <b>61</b>F (see <figref idref="DRAWINGS">FIGS. 12A and 12D</figref>).

<figref idref="DRAWINGS">FIGS. 6 and 8</figref> show an interim state. Before reaching the state shown in <figref idref="DRAWINGS">FIGS. 6 and 8</figref>, first the movable blades <b>62</b>A and <b>62</b>B move from right to left in the figures, with the result that the edges <b>62</b><i>a </i>and <b>62</b><i>b </i>of the movable cutting blades <b>62</b>A and <b>62</b>B come into abutment against the to-be-chipped off portion of the insulated conductor <b>100</b>. As shown in <figref idref="DRAWINGS">FIGS. 12B and 12E</figref>, the edges <b>62</b><i>a </i>and <b>62</b><i>b </i>of the movable cutting blades <b>62</b>A and <b>62</b>B are formed axially longer than the edges <b>52</b><i>a </i>and <b>52</b><i>b </i>of the movable cutting blades <b>52</b>A and <b>52</b>B, so that the insulated conductor can be chipped off over a longer axial portion than the portion which has been cut with the edges <b>52</b><i>a </i>and <b>52</b><i>b </i>of the movable cutting blades <b>52</b>A and <b>52</b>B in the previous process. Consequently, it is possible to solve the problem that the conductor is torn off in the portion of a small sectional area previously chipped off when the edges <b>62</b><i>a </i>and <b>62</b><i>b </i>of the movable cutting blades <b>62</b>A and <b>62</b>B come into abutment against only the said potion of a small sectional area.

Further, as the edges <b>62</b><i>a </i>and <b>62</b><i>b </i>of the movable cutting blades <b>62</b>A and <b>62</b><i>b </i>move toward the combined conductor guide and fixed cutting blade <b>61</b>C, the long-side portions with the sectional area not reduced yet begin to be chipped off by the edges <b>62</b><i>a </i>and <b>62</b><i>b</i>. At this time, the pressing force of the movable cutting blades <b>62</b>A and <b>62</b>B is borne by abutment of an outer face of the axially outer portion of a larger sectional area with respect to the portion chipped off previously by the edges <b>52</b><i>a </i>and <b>52</b><i>b </i>of the movable cutting blades <b>52</b>A and <b>52</b>B against the fixed clamping fixtures <b>61</b>A and <b>61</b>B (see <figref idref="DRAWINGS">FIGS. 12B and 12E</figref>).

Then, as the edges <b>62</b><i>a </i>and <b>62</b><i>b </i>move toward the combined conductor guide and fixed cutting blade <b>61</b>C, the edges <b>62</b><i>a </i>and <b>62</b><i>b </i>reach the face of the portion of a smaller sectional area which was chipped off with the edges <b>52</b><i>a </i>and <b>52</b><i>b </i>of the movable cutting blades <b>52</b>A and <b>52</b>B in the previous process. At this time, the portion chipped off in the previous process and reduced in sectional area undergoes the pressing force of the conductor presser <b>62</b>C and that of the movable cutting blades <b>62</b>A, <b>62</b>B and is deformed leftwards in the drawings. This deformation continues until the groove <b>61</b>F-side face of the portion reduced in sectional area is pressed against the bottom face of the groove <b>61</b>F (see <figref idref="DRAWINGS">FIGS. 12C and 12F</figref>).

After abutment of the groove <b>61</b>F-side face of the portion reduced in sectional area against the bottom face of the groove <b>61</b>F, the conductor is excised with a shear force developed between the edges <b>62</b><i>a</i>, <b>62</b><i>b </i>of the movable cutting blades <b>62</b>A, <b>62</b>B and the edges <b>61</b><i>a</i>, <b>61</b><i>b </i>of the combined conductor guide and fixed cutting blade <b>61</b>C.

<figref idref="DRAWINGS">FIGS. 6 and 8</figref> show an interim state, in which the chipped-off coating and apart of the conductor (chips resulting from cutting) are held in gaps <b>61</b>D and <b>61</b>E formed between the fixed clamping fixtures <b>61</b>A, <b>61</b>B and the combined conductor guide and fixed cutting blade <b>61</b>C.

In <figref idref="DRAWINGS">FIG. 9</figref>, the fixed and movable dies <b>51</b>, <b>52</b> and cutting blades are positioned by positioning pins <b>56</b>A and <b>56</b>B.

<figref idref="DRAWINGS">FIG. 13</figref> shows the insulated conductor <b>100</b> after chipping-off of the short- and long-side enamel coatings. The reference numerals described in <figref idref="DRAWINGS">FIG. 13</figref> are the same as those used for the electric wires (joint conductors) <b>1</b> and <b>2</b> in <figref idref="DRAWINGS">FIG. 1</figref>, indicating the same portions as in <figref idref="DRAWINGS">FIG. 1</figref>.

After the enamel coatings have been chipped off by the excising devices <b>50</b> and <b>60</b>, the pair of electric wires (joint conductors) <b>1</b> and <b>2</b> assume a state in which both are connected together through the projecting portion <b>1</b>C.

The portion of the smallest sectional area is formed by central edge portions of the edges <b>52</b><i>a </i>and <b>52</b><i>b </i>of the movable cutting blades <b>52</b>A and <b>52</b>B when the short-side coating is chipped off. In <figref idref="DRAWINGS">FIG. 13</figref>, the size of a short side is L<b>1</b> and that of a long side is L<b>2</b>, both being in the relation of L<b>1</b>&lt;L<b>2</b>.

A cutting device is disposed at a position just behind the chip-off device <b>60</b> on the machining line. When the chipping-off is completed by the chip-off device <b>60</b>, the electric wires are fed up to the position of the cutting device.

<figref idref="DRAWINGS">FIG. 14</figref> is a sectional view taken along line P-P in <figref idref="DRAWINGS">FIG. 13</figref>, showing a state in which the insulated conductors are set to the cutting device.

As shown in <figref idref="DRAWINGS">FIG. 14</figref>, the cutting device includes a cutting blade <b>110</b> and cut assisting fixtures <b>111</b> disposed on both sides of the cutting blade <b>110</b>. The cut assisting fixtures <b>111</b> function not only as guides for the cutting blade <b>110</b> but also as holding fixtures for holding the conductors firmly. In a state in which the conductors are pressed against a receiving die <b>112</b> by the cut assisting clamping fixtures <b>111</b>, the cutting blade <b>110</b> is moved toward the receiving die <b>112</b>, whereby the portion of the smallest section is cut to form a projecting portion <b>1</b>C.

At this time, the faces of the electric wires (joint conductors) <b>1</b> and <b>2</b> which faces are in contact with the receiving die <b>112</b> form joined faces <b>1</b>H and <b>2</b>H after the cutting. As shown clearly in <figref idref="DRAWINGS">FIG. 14</figref>, the joined faces <b>1</b>H and <b>2</b>H are deformed (offset to one side from the center) so as to be flush (coplanar) with the faces of the enamel coatings <b>1</b>B and <b>2</b>B.

Although in the above embodiment the enamel coating-chipped off portions are thus deformed (offset to one side from the center) simultaneously with the chipping-off of the long-side enamel coating, there may be adopted a method wherein the portions in question are not deformed (offset to one side from the center), but are pressed and deformed longitudinally as indicated with broken lines by pressing fixtures <b>113</b> and <b>114</b> in the cutting process, as shown in <figref idref="DRAWINGS">FIG. 15</figref>, followed by cutting of the portion of the smallest section with use of the cutting blade <b>110</b>.

<figref idref="DRAWINGS">FIG. 16</figref> illustrates coil conductors in a stator of a rotary electric machine which is provided with the electric wires (joint conductors) shown in <figref idref="DRAWINGS">FIGS. 1</figref>, <b>13</b> and <b>14</b>.

The coil conductors, which constitute a stator in the rotary electric machine, are an inner coil <b>131</b> inserted inside a slot of the stator, an outer coil <b>133</b> inserted outside the slot, and a crossover coil <b>132</b> which provides a connection between the inner and outer coils.

Enamel coating-chipped off portions <b>131</b>A, <b>131</b>B, <b>132</b>A, <b>132</b>B, <b>133</b>A, and <b>133</b>B of the shape described above are formed at both ends of the coil conductors by the above process.

Each coil conductor is bent nearly centrally, as shown in <figref idref="DRAWINGS">FIG. 17</figref>. A description on the bending process will be described later.

As shown in <figref idref="DRAWINGS">FIG. 18</figref>, the inner and outer coils <b>131</b>, <b>133</b> are each formed in a generally hexagonal shape. Twisted portions <b>131</b>C, <b>133</b>C and slant side portions <b>131</b>G, <b>131</b>F, <b>133</b>G, <b>133</b>F form crossover line portions of stator coils.

In the enamel coating-chipped off portions <b>131</b>A, <b>131</b>B, <b>133</b>A, and <b>133</b>B, predetermined joined face portions are joined together at their joined faces, then are cut as in <figref idref="DRAWINGS">FIG. 2</figref>, and thereafter welded as in <figref idref="DRAWINGS">FIGS. 3 and 4</figref>.

The coils thus formed are inserted into slots <b>161</b> of the stator indicated at <b>160</b>, as shown in <figref idref="DRAWINGS">FIG. 19</figref> and are joined by welding in the respective joined face portions to form stator coils.

Next, a process of forming the stator coils <b>131</b>, <b>133</b> and a process of assembling the stator <b>160</b> will be described below with reference to <figref idref="DRAWINGS">FIGS. 20 to 31</figref>.

The coil conductors shown in <figref idref="DRAWINGS">FIG. 16</figref> which serve as base metals of the inner and outer coils <b>131</b>, <b>133</b> are formed in U shape in a U shape forming process (not shown), then in the process shown in <figref idref="DRAWINGS">FIG. 20</figref>, plural U-shaped inner and outer coils <b>131</b>, <b>133</b> are inserted and set into separate inserting fixtures <b>200</b>.

In the process shown in <figref idref="DRAWINGS">FIG. 21</figref>, the U-shaped portions of the plural inner and outer coils <b>131</b>, <b>133</b> set in the inserting fixtures <b>200</b> are twisted by twisting fixtures <b>210</b>.

In the process shown in <figref idref="DRAWINGS">FIG. 22</figref>, a stator core <b>302</b> is set in a stator assembly fixture <b>300</b> provided with a coil guide <b>301</b>.

In the process shown in <figref idref="DRAWINGS">FIG. 23</figref>, the inner coils <b>131</b> are first set using the coil guide <b>301</b> into slots formed in the stator core <b>302</b> which has been set in the stator assembling fixture <b>300</b>.

In the process shown in <figref idref="DRAWINGS">FIG. 24</figref>, the outer coils <b>133</b> are inserted and set into slots formed in the stator core <b>302</b> with use of the coil guide <b>301</b> so as to be positioned outside the inner coils <b>131</b> which have already been set.

<figref idref="DRAWINGS">FIG. 25</figref> shows the stator core <b>302</b> with inner and outer coils <b>131</b>, <b>133</b> set therein.

In this state, joined end portions of the inner and outer coils <b>131</b>, <b>133</b> are not ready for joining yet.

In the process shown in <figref idref="DRAWINGS">FIG. 26</figref>, the outer coils <b>133</b> are first pushed into the stator <b>302</b> with use of a coil pushing jig <b>303</b> and a rotary shaft <b>304</b> is rotated in e direction of arrow, causing a lower die <b>305</b> to rotate and thereby twisting the joining end portions into a predetermined shape.

In the process shown in <figref idref="DRAWINGS">FIG. 27</figref>, the lower die <b>305</b> is removed and terminals of the outer coils <b>133</b> are deformed into a state necessary for joining as in <figref idref="DRAWINGS">FIG. 1</figref>, followed by caulking to effect forming. Thereafter, cutting is performed by the cutting device as in <figref idref="DRAWINGS">FIG. 2</figref> and preparations are made for welding.

In the process shown in <figref idref="DRAWINGS">FIG. 28</figref>, the joined face portions are welded by Tig welding by the method shown in <figref idref="DRAWINGS">FIGS. 3 and 4</figref>. At this time, a welding height is measured by a sensor <b>306</b> and a check is made to see whether the measured height is an appropriate height or not.

In the process shown in <figref idref="DRAWINGS">FIG. 29</figref>, the inner coils <b>131</b> are pushed into the stator <b>302</b> with use of a coil pushing jig <b>307</b> and the rotary shaft <b>304</b> is rotated in the direction of arrow to rotate the lower die <b>305</b>, thereby twisting the joining end portions into a predetermined shape.

In the process shown in <figref idref="DRAWINGS">FIG. 30</figref>, the lower die <b>305</b> is removed and terminals of the inner coils <b>131</b> are deformed into a state necessary for joining as in <figref idref="DRAWINGS">FIG. 1</figref>, followed by caulking to effect forming. Thereafter, cutting is performed by the cutting device as in <figref idref="DRAWINGS">FIG. 2</figref> and preparations are made for welding.

In the process shown in <figref idref="DRAWINGS">FIG. 31</figref>, the joined face portions are welded by Tig welding by the method shown in <figref idref="DRAWINGS">FIGS. 3 and 4</figref>. At this time, a welding height is measured by the sensor <b>306</b> and a check is made to see whether the measured height is an appropriate height or not.

In this way the stator shown in <figref idref="DRAWINGS">FIG. 19</figref> is obtained.